Method of preparation of supported nickel, cobalt, or copper catalysts



United State Pat Howard L. Farrow, Long Beach, Calif., assignor to Phillips Petroleum Company, a corporation of Delaware No Drawing; Application November 12, 1948, Serial No. 59,761

14 Claims. Cl. 252-463) This invention relates toan improved catalytic material and method of preparing the. same. One aspect of the invention relates to the preparation of an unusually active catalyst comprising nickel, cobalt and/or copper, or the oxides thereof. Another aspect of the invention pertains to the catalytic conversion of hydrocarbons in the presence of the novel catalyst of the inventlon.

This application is a continuation-in-part of my applicatlion gerial No. 395,286, filed May 26, 1941, now abanone It has long been known that nickel, cobalt, and copper may be used as catalysts for a great number of different reactions, some of the more important being hydrogenation, dehydrogenation, reductions of all kinds, desulfurization, and cracking of hydrocarbons. The metals may be used in many different forms, but it is important that the surface area be great, and in an active condition. Therefore, the steps used in preparing the catalyst greatly affect the activity of the finished prodnot.

One of the most desirable ways of using these metals as catalysts is to coat the surfaces of, or impregnate the pores of, a carrier which ordinarily is inert so far as the reaction being catalyzed is concerned, with the active metal. Such carriers may be clays such as fullers earth, gels such as silica gel, porous metal oxides such as activated alumina or bauxite, porcelain, asbestos, pumice, kieselguhr, charcoal, etc. The state of division of the carriers may range from a very fine powder to relatively large lumps. The finished catalyst may be used by agitating it with a liquid which is being treated with hydrogen, or it may be placed in a tower or retaining vessel and the reactants passed over it. Various other methods of contacting catalysts with the materials to be treated are well known. I

Several methods of making such catalysts are discussed below with particular reference to nickel. It should be understood that certain of the methods of the prior art have also been applied to cobalt and copper compounds, and that the preparation of a eatalystaccording to this invention may be carried out using cobalt and copper compounds as well as nickel. I

Customary starting materials for the preparation of supported nickel catalysts are'soluble salts 'such as the sulfate, chloride, acetate, and nitrate of nickel, and complex nickel ammonium salts are sometimes also used. The carrier is impregnated with a solution of the nickel compound or with the molten salt, dried, and then metallic nickel is produced by reducing the nickel compound with a reducing gas, ordinarily hydrogen, although carbon monoxide or hydrocarbons may be used. In another method the carrier is mixed with a solution of the nickel compound, the hydroxide or carbonate of nickel is precipitated, and then the mixture of carrier and hydroxide or carbonate is filtered out, which mixture is subsequently washed free of soluble salts, dried and reduced. In any such methods the nickel compound on the carrier is sometimes first changed to the oxide by heating in-a stream of air before reduction'to metallic nickel.

' Since catalyzed reactions occur at the surface of the catalyst, it is necessary that the surface be highly extended, and that the molecules of the catalyst be in an activated condition. The many different methods of preparing nickel catalysts have been devised with this fact in mind, and the object is to prepare a more finely divided catalyst than has been previously available. For

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this purpose, carbonates appear to be especially desirable, since their decomposition by heating leaves an oxide or metal which is in a finer state of division than oxides or metals prepared from other salts.

Prior art methods which have been heretofore described have various disadvantages which prevent the production of the best possible supported nickel catalyst. Simple impregnation with soluble salts or with molten salts and subsequent reduction gives a good catalyst but the nickel is not in as fine a condition as is desirable for the best results. When an insoluble nickel compound is precipitated in a slurry with the carrier, such as when the hydroxide or carbonate is produced, the carrieris not properly impregnated, since only a part of the precipitation occurs within the pores of the carrier and the major portion of the precipitate ismerely in admixture with the carrier. In the case of the carbonate, and sometimes in the case 'of the hydroxide, the mixed carrier and precipitate must be washed very thoroughly to remove all the soluble salts present. For instance, if nickel ammonium nitrate is treated with sodium carbonate, the sodium nitrate is washed out, which takes a large quantity of wash water and much time.

It is an object of this invention to provide an improved catalyst and a method of preparing the same.

Another object of this invention is to provide a method for preparing a highly active nickel, cobalt, or copper catalyst.

Another object of this invention is to provide a method for preparing a highly active nickel, cobalt, or copper oxide catalyst.

A further object of this invention is to provide an improved method for impregnating a porous carrier with 'catalytically active nickel, cobalt and/or copper.

A still further object, of this invention is to provide a catalyst which is economically prepared and which has more activity per weight of active material than catalysts prepared by other methods.

Yet another object of the invention is to provide an improvement'in catalytic hydrocarbon conversion processes which are catalyzed by nickel, cobalt, and copper catalysts. 7

Other objects andadvantages of this invention over previously known catalysts and their methods of preparation will be apparent from the following detailed description.

It has been found that a highly active finely divided catalyst is produced by a sequence of operations performed under conditions hereinafter more fully disclosed. A metal carbonate is first formed on a carrier in situ from complex metal ammonium salts with which the carrier has been impregnated, by contacting the impregnated carrier with carbon dioxide. -After the formation of the carbonate, it is beneficial first to dry the product at temperatures below those at which decomposition of the carbonate to the oxide will occur; After this drying step the carbonate is then decomposed by heating to a temperature sufficiently high to form the oxide, after which said oxide is subjected to reduction to form the metallic catalyst. While the preliminary lower temperature drying step may be eliminated, it has been found that the inclusion of the step, permitting the decomposi- 'tion to take place in the absence of much moisture,

will produce a more active and hence more desirable catalytic material. The above referred to procedure has been found to be particularly effective in the preparation of metallic nickel, cobalt, and copper "catalysts.

Referring specifically to the production of a nickel catalyst, by way of example, the first step is the formation of a complex nickel ammonium salt in solution. This complex must usually be prepared from a soluble nickel salt of an acid, either organic or inorganic, more volatile than phosphoric acid, such as nitric, acetic, etc. By following certain procedures, however, soluble salts of less-volatile acids such as phosphoric and sulfuric may be used, as is 'hereinaftermore fully disclosed. 1

After the" formation of the complex nickel ammonium salt solution, the porous carrier in a suitable state of subdivision is then soaked in the solution, which may be either hot orcold," until thoroughly impregnated therehydration.

' salt. 'causethehydroxid'e to dissolve...

activated alumina granules having a 'size of about. '4 to' 3 with. The carrier may be in finely divided form, in the form of porous pellets produced by conventional pelleting techniques, or in irregular crushed and screened shapes of varied mesh-sizes selected according to use. Subsequent to the soaking step, the excess solution is removed, and the material is treated with a .gas containing carbon dioxide in order to form a carbonate, which is subsequently heated to drive off volatile matter, and reduced to nickel metal. The treatment with a .carbon-dioXide-containing gas may be. done at a superatmospheric pressure if desired to hasten the carbonation and to insure complete penetration of the catalyst mass by the .gas. The :following conditions .have been found desirable for the treatment with carbon dioxide and subsequent decomposition.

.. Time, Temp.,

Penod Hours 4 C.

Ana.-. -J lCarbonatiou l 6 .30- .B Drying 2 -95 C ecomposltion 2 250-350 variations may be allowed in the time required for each step of the catalyst preparation, depending on the gas flow rates, etc., and some variations in the temperatures may also be permitted, the ranges given here being' merely those which are ordinarily preferred. During the A period, the nickel :arnmonium complex :is converted to nickel carbonate, nickel ammonium carbonate, :and/or basic nickel carbonate, .in varying degrees of During the 'Bt.perio.d, most or :all of the residual water is driven out very slowly, thus avoiding disruption of th'epores of the carrier. Decomposition of nickel carbonate is accomplished by. slowly advancing the temperature to that indicated for the C period.

Here carbon dioxide gas is given off in the .decomposition of the nickel carbonate to form nickel oxide, and

ammonium salts are'volatilized and/or decomposed.

catalyst mass, whereby :said mass is washed substantially free of simple ammonium salts, leaving only the nickel carbonate, nickel ammonium carbonate, and/or 'basic nickel carbonate on the carrier. Following this procedure, the C period is limited :to decomposition of the carbonate to the oxide, since there'are no ammonium salts present to be volatilized. Of course, any ammonia which may have remained combined in a nickel compound will be driven off. The said washing step may also be employed when salts of the more volatile acids are utilized, but it is seldom as efficient as following the 'A, B, and C procedure and volatilizing the ammonium salts.

In any case, after either theA, B, :or C period, but, preferably after the 8" period, if desired, the impregnated carrier may be returned to the solution of the nickel ammonium salt for a time in order to :put .addi- 'tional' active material on the carrier, and the various steps of the catalyst preparation repeated. The use of hydrogen or other reducing gas is' employed as a final step in treating the catalyst at about 300 to 500 C. for about four hours. The metal oxide 'is thus reduced to the metal, with elimination of water, an'd'hydrogen :may then 'be occluded on the catalyst'by cooling in a stream of hydrogen, if that gas is being used.

As an example "showing the preparation .of a catalyst in accordance'with the principles discussed above, I shall describe the preparation of a :niokel catalyst supported 'on activated alumina. One part by 'weight of nickel nitrate hexahydrate crystals was mixed with two parts by weight of water. Sufficient v28 per cent ammonium hydroxide was added to form the complex salt. Upon the initial addition of the ammonium hydroxide, nickel hydroxide precipitated but with continued addition, (the hydroxide dissolved, leaving a solution of the complex Just enough ammonium hydroxide was added to Next, a quantity-of -=8-m"esh, previouslyYheated .to 1120 C, was placed in the solution and allowed to remain therein at room temperaadvantage over processes of the prior art.

ture for a period of 7 hours. The excess solution was then drained OE and the wet catalyst mass was placed in a vertical tower and heated to 35 C. while a slow stream of carbon dioxide was passed upwards through the tower at atmospheric pressure. After 6 hours of this treatment, the heat to the tower was increased and the tower temperature rose to C. within about one hour, and increased to C. 'in the next hour, with carbon dioxide still passing through. Next, the temperature was increased "to 150 C. in one hour, and to 300 C. in the next hour. A slight flow of hydrogen was then started into the tower along with the carbon dioxide and the hydrogen flow was gradually increased while the carbon dioxide flow was decreased "so that within one hour only hydrogen was passing over the catalyst mass. Meanwhile, the temperature was increased .to 400 C., and then further increased to 450 C. 'within the next hour and allowed to remain at that temperature for two more hours. The finished catalyst was then cooled in the presence of hydrogen.

In order to test 'its'utility as a hydrogenation catalyst, the catalyst thus prepared was :used in the hydrogenation of a dewaxed lubricating oil. 'The fines were screened "from the catalyst, and the .oil was placed along with the catalyst in a pressure bonib. Hydrogen was admitted to a pressure of 5,000 pounds per squareinch gage and the bomb was held (at 345 C. androcked back and forth. At the end of two hours, the rocking was stopped, the pressure was released and the oil was separated from the catalyst. The data below show the properties of the hydrogenated o'il compared to the properties of the unhydrogena'ted oil. It is apparent from the Indiana accelerated oxidation ftestthat a very stable lubricating oil was obtained from the hydrogenation.

Charge waxed on Gravity A P I .27. s 2s. a Flash, F 440 440 Fire, F 520 515 Pour Point, F 5 5 Saybolt Viscosity: F...

Viscosity Increase 50 hours 90 hours ring some of the metal, since only .the surface is eflective.

Amorercomplete impregnation of all the pores is accomplished by using solutions rather than molten salts. The use of the complex .ammoniurn compound has a number of advantages. The ammoniacal solution has a lower viscosity than other solutions of the metal salts, and of course a much lower viscosity than molten salts, and

. thus penetration of the-carrierpores is facilitated. Solutions of the complex ammonium salts are much less corrosive than the corresponding solutions :of the simple .salts, and thus .may be stored, pumped, and otherwise handled-more economically-and conveniently.

The carbonation period of this invention has -.a dual In .the "first place, carbon dioxidegas easily penetrates into all of the pores of the carrier, thus effecting the-completeforma- -tionof :the metal carbonate and/or basic .carbonate in -:situ. Not only is all of the metal present .on the carrier converted, but there is.no mechanical floss ofthe carbonate from =.the pores-'snch.as-occturslif.1he carbonation is carried out while the catalyst mass is suspended in a liquid,

as taught by the prior art. Thus, the pores of'the carrier are first impregnated with a soluble salt and the carbonate, oxide, and finally. mcial subsequently formed are always in the most satisfactory form of a highly extended surface film. Furthermore, no additional precipitate is mixed mechanically with the carrier to clog the pores and form a thick, wasteful, and less active film. In the second place, no washing step of any kind is ordinarily necessary. When salts other than nickel, cobalt or copper compounds are present, which occurs when the carbonate is precipitated according to previously known methods, the prior art teaches that it is important that the catalyst mass undergo a very complete washing for the purpose of eliminating such salts, since their presence even in quite minor amounts greatly inhibits or destroys the catalytic action. step are so obvious that it is hardly necessary to discuss them. However, when a carbonate catalyst is prepared according to the present invention, the undesired salts are merely volatilized and/or decomposed during the decomposition or reduction period. As previously explained, it may be found desirable occasionally to wash out these volatile salts rather than to eliminate them by heating. This can, of course, be done by passing Water through the catalyst mass after the carbonation period. This is a relatively simple procedure since the metal carbonate is held in the p res of the carrier and filtration .is unnecessary. Ordinarily though, in the case of salts of the more volatile acids. it is better to avoid the washing process and to use heat for removal of ammonium salts.

A further explanation of the process involved in the utilization of salts of the less-volatile acids will now be given. If nickel sulfate, for instance, is used. the ammonium sulfate formed during the carbonation period would break down on heating to give ammonia gas and sulfuric acid. The sulfuric acid being relatively nonvolatile would remain in the catalyst mass and nickel sulfate would be formed. the reduction of which to nickel oxide or nickel metal is almost impossible under the ordinary conditions of catalyst formation. Thus. it is impractical for reparing a nickel catalyst. especially since even very small amounts of residual sulfur would act as a poison. The same principles apply to the use of phosphates. Thus, a washing step is necessary to eliminate the ammonium salts of such relatively non-volatile acids and economic considerations will dictate the choice of starting materials in view of the extra step .which may be involv d in the catalvst preparation.

The drying eriod of this invention is of considerable importance. For the best results, the water should be driven off slowly so that the pores of the catalvst, or the gel structures as the case may be. are not br ken up by the rapid formation and esca e of steam. The presence of the carbon dioxide durin this step is desirable in order to assure the comple ion of the change from the nitrate or other salt to the carbonate. The temperatures of drying are such that no app eciable dec mposition of the carbonate to form the o ide occurs. althou h various changes in the composition of the com lex molecules occur, such as l ss of varying amounts of water of hydration. ammonia. and sometimes loss of some carbon dioxide to give hvdroxides. etc. However, no metal oxide is formed.

During the decomposition period. it is not essential that carbon dioxide be passed over the catalyst, although it is somewhat desirable to do so during the early part of the period when some moisture may still be present. Air may be used, and only suflicient gas need be passed during this period to sweep away the vapors from the volatile salts and the carbon dioxide formed by decomposition of the carbonate. It is appreciated that the decomposition of ammonium salts on heating will give some free acid which in turn may react with nickel carbonate to re-convert the nickel to a salt of the liberated acid. However, a certain amount of such action will not affect undesirably the properties of the finished catalyst. Because of the absence of an appreciable amount of water, it is believed that the reaction between the liberated acid and the nickel carbonate does not occur to any great extent.

When reduction of the oxide is started, it is very imp rt nt that hydrogen be admitted slowly. The reaction is exothermic, and so much heat may be generated at the catalyst surface during the early part of the reduction that sintering of the catalyst may occur, with consequent seri- The disadvanta es of such a washing bonate.

ous 'lossin activity. The procedure described in the example above is a very satisfactory method of handling this important part of the catalyst preparation. Other means for the prevention of overheating during reduction can, of course, be used, such as applying vacuum to the catalyst mass, and then slowly admitting hydrogen, or the flow may be made very small until the major portion is reduced, or other gases than carbon dioxide may be used as diluents for the hydrogen or other reducing gas. It is not desirable to heat the catalyst to a temperature higher than that required for complete reduction. Contrary to some previous teachings, it is not always necessary to effect a complete reduction, since the presence of some oxide may be found desirable. The use to which the catalyst is put will determine whether complete reduction is essential. In some cases, for instance in the hydrogenation of polymer gasoline, the reaction mixture may be passed directly over the supported oxide, and the reduction takes place while the hydrogenation proceeds.

If the finished catalyst is cooled before use, it is best to do this in the presence of hydrogen. The occlusion of hydrogen in this manner seems to improve the activity in hydrogenation and other reductions. Also, it is desirable to avoid contacting the active metal with air, otherwise poisoning by means of oxygen may occur. Of course, since even small traces of sulfur and halogens will poison such catalyst, care should be taken throughout the various steps of preparation to protect the material being worked on from contamination with material containing such poisons.

An advantageous method of making a catalyst in conformity with the teachings of this invention is to use flue gas, or similar industrial gases, containing appreciable quantities of carbon dioxide, rather than carbon dioxide gas alone. Such a gas is usually available in almost any industrial plant at a negligible cost. The only necessary precaution is that it not contain poisoning substances, such as carbon monoxide or sulfur compounds. A purification of the gas would be necessary in order to remove such poisons if present.

Another method of preparing a catalyst by using the principles of this invention is to impregnate a carrier with an aqueous solution of nickel, cobalt, or copper salt, and then to pass over the impregnated carrier a gas containing both carbon dioxide and ammonia to form the metal car- The subsequent steps are then accomplished in any manner hereinbefore described.

Of course some reactions are catalyzed by a metal oxide catalyst, and the advantages inherent in the preparation herein described are available for the productionof supported nickel, cobalt, and copper oxides.

I claim:

l. A process for the preparation of a supported catalyst, which comprises impregnating a porous carrier with an aqueous solution of a complex ammonium salt of a metal selected from the group consisting of nickel, cobalt and copper, removing the excess solution from the impregnated carrier, treating said impregnated carrier with a gas comprising essentially carbon dioxide to precipitate a substantial proportion of the complex metal ammonium salt in the presence of water as a metal carbonate on the carrier, drying the resulting product at a temperature within the range of 65 C. to C., thereafter heating said product in the absence of a reducing gas at a temperature within the range of 250 to 350 C., to convert the metal carbonate to metal oxide, and subsequently heating the resulting product in the presence of a reducing gas at a temperature within the range of 300 to 500 C., to convert the metal oxide to catalytically active metal.

2. A process for the preparation of a supported nickel catalyst, which comprises impregnating a porous carrier with an aqueous solution of a complex nickel ammonium salt, removing the excess solution from the impregnated carrier, treating said impregnated carrier with a gas essentially comprising carbon dioxide to precipitate a substantial proportion of the complex nickel ammonium salt in the presence of water as a nickel carbonate on the carrier, drying the resulting product at a temperature within the range of 65 to 95 C., thereafter heating said product in the absence of a reducing gas at a temperature within the range of 250 to 350 C., to convert the nickel carbonate to nickel oxide, and subsequently heating the resulting product in the presence of hydrogen at a temperature within the range of 300 to 500 C., to convert the nickel oxide to catalytically active nickel metal.

A pro'cessior the preparation ofra supported'cohalt catalyst, which comprises impregnating a porous, carrier with an aqueouss'olution of a complex cobalt ammonium .salt, removing the excess solution from the impregnated perature within thezrange of 300 to 500 C., to convert E the cobalt oxide to catalytically active cobalt.

4. A process for the preparation of asupported copper catalyst which comprises impregnating a porous carrier with an aqueous solution of a'complex copperammonium salt, removing the excess solution from the impregnated carrier, treating said impregnated carrier with a-gas comprising essentially carbon dioxide to precipitate :a substantial proportion of the complex copper ammonium'salt in thepresenceof water as acopper carbonateon the carrier, drying theresulting product .at a temperature within 'the'range of 65 to 95 C., thereafter heating saidproduct inthe absence of a reducing gas at a temperature within the range of 250 to 350 C., to convert the copper carbonate to copper oxide, and subsequently heating the resulting product in the presence of hydrogen at a temperature within the range of 300 to 500 C., to convert the copper oxide to catalytically active copper.

5. vA process for the preparation of a supported catalyst, which comprises impregnating a porous carrier with an aqueous solution of a complex ammonium salt of a a metal selected from the group consisting of nickel, cobalt and copper, removing the excess solution from the impregnated carrier, treating said impregnated carrier with a 'gas comprising essentially carbon dioxide to precipitate a substantial proportion of the complex metal ammonium salt in 'thepresence of water as a metal carbonate on the carrier, drying the resulting product at a temperature within the range of 65 C. to 95 C., and thereafter heating said product in the absence of a reducing gas at a temperature within the range of 250 to 3'50 C., to convert the metal carbonate to metal oxide.

6. A process for the preparation of a supported nickel catalyst, which comprises impregnating a porous carrier with an aqueous solution of a complex nickel ammonium salt, removing the excess solution from the impregnated carrier, treating said impregnated carrier with a gas essentially comprising carbon dioxide to precipitate asubstantial proportion of the complex nickel ammonium salt in the presence of water as a nickel carbonate on the carrier,

drying the resulting product at a temperature within the range of 65 to 95 C., and thereafter heating said product in the absence of a'reducing gas at a temperature within the range of 250 to 350 C., to convert the nickel carbonate to nickel oxide.

18 *7. tAyprocess .-for the preparationof a supported cobalt catalyst, which comprises impregnating a porous carrier with anaqueous solution of a complex cobalt ammonium salt, removing the excess solution from the impregnated -carrier,.treating.said impregnated carrier with a gas com- ;prising essentially carbon dioxide to precipitate a sub stantial proportion of the complex cobalt ammoniumsalt in the presence of. water as a cobalt carbonate on the carrier, drying the resulting product at a temperature within the range of 65 to 95 C., and thereafter heating said product in the absence .of a reducing gas at a temperature within the range of 250 to 350 C., to convert the cobalt carbonate to cobalt oxide.

8. .A processfor the preparation of a supported copper catalyst which comprises impregnating a porous carrier with an aqueous solution of a complex copper ammonium .salt, removing the excess solution from the impregnated carrier, .treatingsaid impregnated carrierwith a gas comprising essentially carbon dioxide to precipitate a substantial proportion of the complex copper ammonium salt in the presence of water as a copper carbonate on the carrier, drying the resulting .product at a temperature within the range of 65 to 95 C., and thereafter heating said product in the absence of a'reducing gas at a temperature within therange of 250 to 350 C., to convert the copper carbonate to copper oxide.

.9. The process of claim 2 in which the porous carrier is anactivated alumina.

10. The process of claim 3 in which theporous carrier is an activated alumina.

11. The process of claim 4 in which the porous carrier is an activated alumina.

12. The process of claim 6.in which the porous carrier is an activated alumina.

13. The process of claim 7 .in which the porous carrier is an activated alumina.

14. The process of claim 8 in which the porous carrier is .an activated alumina.

References Cited in the file of this patent UNITED STATES PATENTS Number Name Date 1,084,258 Ellis Jan. 13, 1914 1,122,811 Snelling Dec. 29, 1914 1,156,674 Ellis Oct. 12, 1915 1,158,664 Ellis Nov. 2, 1915 1,956,585 Oglesby et a1. May 1, 1934 2,118,001 Andrews et al May 17, 1938 2,184,235 Groll et a1. Dec. 19, 1939 2,258,786 Melaven et al. Oct. 14, 1941 2,267,735 Ipatiefi et a1 Dec. 30, 1941 2,289,916 Komarews'ky July 14, 1942 2,322,095 Schmidt June 15, 1943 2,328,719 Houghton et a1. Sept. 7, 1943 2,348,418 Roesch et al May 9, 1944 2,392,107 Teter Jan. 1, 1946 

1. A PROCESS FOR THE PREPARATION OF A SUPPORTED CATALYST, WHICH COMPRISES IMPREGNATING A POROUS CARRIER WITH AN AQUEOUS SOLUTION OF A COMPLEX AMMONIUM SALT OF A METAL SELECTED FROM THE GROUP CONSISTING OF NICKLE, COBALT AND COPPER, REMOVING THE EXCESS SOLUTION FROM THE IMPREGNATED CARRIER, TREATING SAID IMPREGNATED CARRIER WITH A GAS COMPRISING ESSENTIALLY CARBON DIOXIDE TO PRECIPITATE A SUBSTANTIAL PROPORTION OF THE COMPLEX METAL AMMONIUM SALT IN THE PRESENCE OF WATER AS A METAL CARBONATE ON THE CARRIER, DRYING THE RESULTING PRODUCT AT A TEMPERATURE WITHIN THE RANGE OF 65* C. TO 95 C., THEREAFTER HEATING SAID PRODUCT IN THE ABSENCE OF A REDUCING GAS AT A TEMPARATURE WITHIN THE RANGE OF 250* TO 350* C., TO CONVERT THE METAL CARBONATE TO METAL OXIDE, AND SUBSEQUENTLY HEATING THE RESULTING PRODUCT IN THE PRESENCE OF A REDUCING GAS AT A TEMPERATURE WITHIN THE RANGE OF 300* TO 500* C., TO CONVERT THE METAL OXIDE TO CATALYTICALLY ACTIVE METAL. 